CATERPILLAR’ e Troubleshooting G3600 Engines @ 3XF1-UP 4WF1-UP 4CG1-UPImportant Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. ‘The hazards are identitied by the "Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER’, ‘WARNING’ or “CAUTION’. The Safety Alert “WARNING” label is shown below. ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or Pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot sricgat very possible skoumstance thet might ruc a pater] hazard The this publication and on the product are, therefore, not all inclusive. Ifa tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the Product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. ‘The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most Current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F When replacement parts are required for this product Caterpillar recommends using Caterpil- \cement parts or parts with equivalent ‘specifications including, but not limited to, phys~ ns, type, strength and material. Failure to heed this warning can lead to prema- {ure failures, product damage, personal injury or death,G.3600 Engine Supervisory System 08 BOOS 8 How To Use This Manual + Talk tothe operator directly. if possible. ‘What happened and in what order (be spectic) * Under what operating conditions does the problem occur? * What are the operational symptoms and when dd they begin? ‘+ Check the engine repair history ‘+ Is the control system performing as expected? Section 1: System Overview ‘+ Are there any control module diagnostics? ‘= Can the conditions and problems be repeated? ‘Determine all of the diagnostic codes that are present (refer to Accessing Diagnostic Codes) = RECORD DIAGNOSTIC CODES (in order of occurrence) BEFORE THEY ARE CLEARED ANDIOR THE SYSTEM IS RESET! ‘+ Repair all Diagnostic Code problems immediately! ‘= See Section 4: Troubleshooting with a Diagnostic Code. H. ‘There is an LED flashing on the CMS. ‘There isa diagnostic code on the ECM ‘There is an LED illuminated on the TCM. ‘There is an LED illuminated or a IAG code on the SoM, ‘+ There is a problem with the Digtal Diagnostic Tool ‘+ Use operator information gathered above, ‘= Check for LOGGED diagnostic codes = If more than one symptom, are there any common causes? AVOID PRE-CONCEIVED IDEAS! Test the most likely cause first. Perform a visual inspection of the engine components. Use the troubleshooting procedures inthis manual Connector checks are extremely important, check every pin and wire in the connector Troubleshooting